Automotive / Engine Parts

Liner

Outer diameters at different locations, Collar Depth & Collar Width

Client Profile

Kusalava , India Pistons are the leading manufacturers of critical engine parts, supplying to major OEM’s in India, USA & Europe.

Objectives

All measurement of OD and other parameters without manual intervention

Provide a measurement solution to bring accurate and consistent measurement.

eSya solution

Multi gauge

Develop comparator based multi-gauging system. Fixture developed to operate and measure multiple parameters at one go with ease.

Data acquisition

In-house built, microcontroller based data acquisition and Signal processing modules to support measurement data acquisition

Measurement , SPC & Reporting software

Custom built measurement software helps in capturing data and display analyzed outputs. Data collected is analyzed and reported with various trend charts, which will assist in improving process capabilities.

Highlights

16 probes used for measurement of OD, collar depth and width

Speed of measurement and decision making

No Operator skill dependency, as it is simplified

100% rejection is identified

Piston

Piston Outer diameters, Groove Diameter, Groove Width, Pin Bore & Compression Height

Client profile

Federal Mogul & India Pistons Ltd: Manufacturer of world-class pistons, piston rings, sintered parts and cylinder liners covering a wide range of applications

Parameters

• Piston Outer Diameter
• Piston Groove Diameter
• Piston Groove Width
• Compression Height
• Pin Hole Diameter
• Circlip Groove Distance
• Circlip Presence Absence Poke Yoke
• Fixture Seat Diameter
• Piston Pin between chamfer distance
• Piston Ring Outer Diameter
• Piston ring thickness

Solution Highlight

All above requirements are integrated with data collection, SPC analysis and management report packages

Few additional automations like Auto Grade Segregation, Laser Marking, rejection poke yoke are provided for process efficiency

Connecting Rod

SE Diameter, BE Diameter, Centre Distance, Bend & Twist

Client profile

Sansera is the leading Tier-1 Auto Component manufacturer

Parameters

• Big End Diameter
• Small End Diameter
• Center Distance
• Boss Thickness
• Boss Parallelism
• Oil hole presence & absence
• Axis Bend
• Axis Twist
• Conrod bolt hole distance
• Conrod bolt hole parallelism
• Connrod Cap thickness

Solution Highlight

All above measurement are integrated with automation for loading, unloading, marking, segregation for mass manufacturing

Data collected for SPC & Reporting

Crank & Camshafts

Pin Outer Diameter, OD & ID axis parallelism

Client profile

Sansera & SFL, are the leading Tier-1 Auto Component manufacturers

Parameters

• Pin Outer Diameter
• Center Distance
• ID & OD axis parallelism calculated for know distance

Solution Highlight

Complex 8-jet air mandrills are incorporated to measure ID & OD axis bend & twist, expressed as axis parallelism extrapolated to gauging distanc

Data collected is analyzed and reported with various trend charts, which will assist in improving process capabilities.

Cam base Diameter, Cam throw, journal diameters, angle with reference to Key slot

Client profile

Ashok Leyland, one of the leading heavy commercial vehicle manufacturer

Parameters

• Cam throw max calculated with rotation
• Journal Diameters for all Cylinders
• Base Diameters & throw angle

Solution Highlight

Sophisticated Auto rotation system with integrated high precision rotary encoder to measure angles with micron accuracies

High speed Data acquisition up to 4KS/s with latest technology digital probes

Tappet

Shim Selection System for Tappet Seating & Cam Shaft Throw

Client profile

Ashok Leyland, one of the leading heavy commercial vehicle manufacturer.

Parameters

• Cam throw max calculated with rotation
• Cyl. Head journal seat to tappet face distance
• Cylinder specific calculated shim thickness

Solution Highlight

Complex shim selection automated shim selection with lookup table built in to software

Positive poka-yoke shim selection with cross verification

Data acquisition and transfer using RS 232 and zigbee wireless to centralized server

Custom built measurement software helps in capturing data and display analyzed outputs.

Data collected is analyzed and reported with various trend charts, which will assist in improving process capabilities.

Tappet Outer Diameter, Internal Diameter, Boss Thickness, Seating face Concavitiy

Client profile

General Motors / Bhavani one of the leading commercial vehicle manufacturer. and OEM supplier

Parameters

• Tappet Outer Diameter at different Locations
• Internal Diameter
• Boss Thickness
• Geometrical parameters seating face Concavity
• Run-out, Ovality and Taper

Solution Highlight

Positive poka-yoke rejection segregation with RED box concept

Data acquisition and transfer using RS 232 and zigbee wireless to centralized server

Engine Valves

Valve Shaft Diameter, Valve Seat Diameter, Valve Seat Run-out & Length

Client profile

Rane Valves, KAR Mobiles are of the leading heavy commercial vehicle manufacture

Parameters

• Valve Shaft Diameter
• Valve Seat Diameter
• Overall Length
• Groove Distance
• Valve seat run-out & face out

Solution Highlight

Automatic auto rotation system with high precision bearing system to calculate run-out and face out

Flexi model system to incorporate various models of valves

High speed data collection & measurement system